Abstract The limitations of electric vehicles equipped with electrochemical batteries justify strong research interest for new solutions, based on hydrogen fuel-cell technology that are able to improve vehicle range, and reduce battery recharging time, while maintaining the crucial advantages of high efficiency and local zero emissions. The best working of a fuel-cell propulsion system, in terms of optimum efficiency and performance, is based on specific strategies of energy management, that are designed to regulate the power flows between the fuel cells, electric energy-storage systems and electric drive during the vehicle mission. An experimental study has been carried out on a small-size electric propulsion system based on a 2.5-kW proton exchange membrane fuel cell stack and a 2.5-kW electric drive. The fuel-cell system has been integrated into a powertrain comprising a dc–dc converter, a lead–acid battery pack, and brushless electric drive. The experiments are conducted on a test bench that is able to simulate the vehicle behaviour and road characteristics on specific driving cycles. The experimental runs are carried out on the European R40 driving cycle using different energy-management procedures and both dynamic performance and energy consumption are evaluated.
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